Two-stage gasifier and gasification process with feedstock flexibility

ABSTRACT

A gasification process may include (a) introducing a liquid hydrocarbon feedstock and at least one of a dry feedstock or a first slurried feedstock into a reactor lower section, wherein the at least one dry feedstock or first slurried feedstock is introduced through two primary feed nozzles while the liquid hydrocarbon feedstock is introduced through at least two secondary feed nozzles; (b) partially combusting the feedstocks in the reactor lower section with a gas stream comprising an oxygen-containing gas or steam to evolve heat and form products comprising hot synthesis gas; (c) passing said hot synthesis gas from step (b) upward into a reactor upper section; (d) and introducing a second slurried feedstock into said reactor upper section, whereby heat from said hot synthesis gas supports reaction of the second slurried feedstock by pyrolysis and gasification reactions.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. patent application Ser. No.62/303,628 filed on Mar. 4, 2016, which is incorporated herein byreference.

BACKGROUND

Gasification processes are widely used to convert solid or slurriedfeedstocks such as coal, petroleum coke and petroleum residue intosynthesis gas. Synthesis gas is predominantly composed of hydrogen gas(H₂) and carbon monoxide (CO), and is utilized both as fuel for theproduction of electricity, as well as a feedstock for producingchemicals such as hydrogen, methanol, ammonia, synthetic/substitutenatural gas or synthetic transportation oil. Three basic types of systemand processes have been developed for the gasification of carbonaceousmaterials. They are: (1) fixed-bed gasification, (2) fluidized-bedgasification, and (3) suspension or entrainment gasification,Embodiments herein relate to the third type of system and, moreparticularly, embodiments presented herein relate to a two-stageentrained gasification system and process for gasifying carbonaceousmaterials.

The possibilities presented by the two-stage gasifier design can beexploited by maximizing the slurry feed rate to the lower temperaturesecond stage, thereby utilizing the heat generated in the first stagegasifier to evaporate water from the slurry. The char and unconvertedcarbon exiting the second stage gasifier are then separated and recycledback to the first stage gasifier in dry form, thus minimizing the amountof oxygen required in the higher temperature first stage and maximizingthe conversion efficiency of the gasifier.

SUMMARY

This summary is provided to introduce a selection of concepts that arefurther described below in the detailed description. This summary is notintended to identify key or essential features of the claimed subjectmatter, nor is it intended to be used as an aid in limiting the scope ofthe claimed subject matter.

In one aspect, embodiments disclosed herein relate to a gasificationprocess that includes (a) introducing a liquid hydrocarbon feedstock andat least one of a dry feedstock or a first slurried feedstock into areactor lower section, wherein the at least one dry feedstock or firstslurried feedstock is introduced through two primary feed nozzles whilethe liquid hydrocarbon feedstock is introduced through at least twosecondary feed nozzles; (b) partially combusting the feedstocks in thereactor lower section with a gas stream comprising an oxygen-containinggas or steam to evolve heat and form products comprising hot synthesisgas; (c) passing said hot synthesis gas from step (b) upward into areactor upper section; (d) and introducing a second slurried feedstockinto said reactor upper section, whereby heat from said hot synthesisgas supports reaction of the second slurried feedstock by pyrolysis andgasification reactions.

In another aspect, embodiments disclosed herein relate to a two-stagegasification reactor that includes a reactor lower section that includesa lower reactor body; two primary feed nozzles, configured to introduceat least one of a dry feedstock or a first slurried feedstock, locatedon opposing terminal ends of the lower reactor body; and at least twosecondary feed nozzles, configured to introduce a liquid hydrocarbonfeedstock, located on the lower reactor body; a reactor upper sectionthat includes an upper reactor body; at least one upper feed nozzle,configured to introduce at least one of a dry feedstock or a firstslurried feedstock, located on the upper reactor body; and an outlet.

In yet another aspect, embodiments disclosed herein relate to a methodfor improving a two-stage gasification reactor that includes installingat least two secondary feed nozzles on a lower reactor body forintroducing a liquid hydrocarbon feedstock into the lower reactor bodyto supplement a primary feedstock comprised of a dry feedstock or aslurried feedstock that is introduced through a primary feed nozzle.

Other aspects and advantages of the claimed subject matter will beapparent from the following description and the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic representation of a gasification system employinga conventional two-stage gasification reactor.

FIG. 2 is a side perspective view of one half of a lower section of atwo-stage gasification reactor of an embodiment of the presentdisclosure.

FIG. 3 is a top perspective view of one half of a lower section of atwo-stage gasification reactor of an embodiment of the presentdisclosure.

FIG. 4 is an end perspective view of one half of a lower section of atwo-stage gasification reactor of an embodiment of the presentdisclosure.

DETAILED DESCRIPTION

In one aspect, embodiments disclosed herein generally relate to agasification process that converts carbonaceous feedstock into desirablegaseous products such as synthesis gas. In more particular aspects,embodiments disclosed herein relate to a gasification process withfeedstock flexibility when converting carbonaceous materials intodesirable gaseous products. For instance, in one or more embodiments, agasification process disclosed herein may utilize a liquid hydrocarbonfeedstock and at least one of a dry feedstock or a slurried feedstocksimultaneously within the reaction chamber of a gasifier.

Referring to FIG. 1, an embodiment of a gasification system employing aconventional two-stage gasification reactor is shown, indicatedgenerally by reference numeral 10. The gasification system has a reactorlower section 30 and a reactor upper section 40. The first stage of thegasification process takes place in the reactor lower section 30 and thesecond stage of the gasification process takes place in the reactorupper section 40. The reactor lower section 30 defines the first stagereaction zone, and will alternatively be referred to as the first stagereaction zone. The reactor upper section 40 defines the second stagereaction zone, and will alternatively be referred to as the second stagereaction zone.

Referring to FIG. 1, a gasification process generally begins within thefirst reaction zone (or reactor lower-section 30), when a dried orslurried carbonaceous feedstock is mixed with a gas stream comprising anoxygen-containing gas and/or steam and a rapid exothermic reaction takesplace in which the carbonaceous feedstock is converted into a firstmixture product comprising steam, hydrogen, carbon monoxide, carbondioxide, methane, and entrained particulates such as ash. Ash beingcomprised of the non-combustible mineral content of the carbonaceousfeedstock. In one or more embodiments, a solid carbonaceous feedstockmay be pulverized (by methods that are known in the art, but outside thescope of this disclosure), and in some instances slurried, beforeentering a feeding system 100 such as, but not limited to, a lock-hoppersystem, The pulverized solid stream comprising particulate carbonaceousmaterial from the feeding system 100 is injected into the gasificationreactor 10 lower section 30 through feed nozzles 60 and/or 60 a. Thetemperature of the first reaction zone 30 is maintained higher than theash melting point, which allows the ash to melt and agglomerate to forma viscous liquid known as slag. The slag falls to the bottom of thereactor lower-section 30 and flows into a quench chamber 32, whereuponit is water quenched and directed to a slag processing system (notshown) for final disposal.

The primary combustion reaction occurring in the first reaction zone is:

C+1/2O₂→CO,

which is highly exothermic. The exothermicity of the reaction raises thetemperature in the first reaction zone to between 2000° F. and 3500° F.The heat produced in the first reaction zone is carried upward with thegas stream, thereby providing heat for pyrolysis reactions that occur inthe unfired second reaction zone, including vaporization of the feedwater, the carbon-steam reaction and the water-gas reaction between COand H₂O. The carbon-steam reaction forms CO and H₂, thus, increasing theyield of these usable gases.

Concerning the reactor upper section 40, according to the embodimentdepicted in FIG. 1, solid carbonaceous feedstock may be pulverized (bymethods that are known in the art, but outside the scope of thisdisclosure), and in some instances slurried, before entering feedingsystem 100, also used to feed reactor lower section 30. The pulverizedsolid stream comprising particulate carbonaceous material from thefeeding system 100 may be injected into the gasification reactor 10upper section 40 through upper feed nozzle 80, or additional feednozzles (not shown). The carbonaceous material then comes into contactwith the hot syngas rising from (and produced within) the gasificationreactor 10 lower section 30. The carbonaceous material entering theupper section 40 is dried and a portion of it is pyrolyzed and gasifiedvia reactions such as the carbon steam reaction (C+H₂O→CO+H₂). Pyrolysisand gasification reactions are endothermic, thus, the temperature of themixture of carbonaceous material and syngas decreases as the mixturetravels upwards through the upper section 40, By the time the secondmixture product comprising un-reacted solid particulates (e.g. char) anda second gaseous product stream (e.g. syngas) leaves the top of theupper section 40 of the gasifier 10, the second mixture producttemperature drops to the range between 1200° F. and 2500° F., such aswithin the range between 1500° F. and 2000° F.

Further according to the embodiment as shown in FIG. 1, the secondmixture product, produced in the reactor upper section and comprisingun-reacted solid particulates and a second gaseous product stream, exitsthe reactor upper section 40 and is sent to a heat recovery unit 180.Subsequently, the cooled syngas is introduced to a particulate filteringdevice 50. Within the particulate filtering device 50, the second solidproduct stream is separated and withdrawn via an outlet 70. The secondsolid product stream (primarily including char) may then be recycledback to the reactor lower section 30 of the gasifier 10 via feed nozzles90 and 90 a and used to supplement the carbonaceous feedstock introducedtherein from feed nozzles 60 and 60 a.

Further referring to FIG. 1, the gaseous product stream 52 exiting fromthe particulate filtering, device 50 comprises hydrogen, carbonmonoxide, a small amount of methane, hydrogen sulfide, ammonia,nitrogen, and carbon dioxide, which constitutes the process product. Inone or more embodiments, the process product stream exits particulatefiltering device 50 to undergo further processing (e.g., separations,scrubbing, etc.) for end-use applications.

Referring now to FIGS. 2-4, embodiments of the present disclosure willbe explained in further detail. In general, the reactions occurringwithin the gasification reactor are the same as what has been describedabove, although the gasification reactor and its operation have beenmodified to improve feedstock flexibility. Shown in FIGS. 2-4 areperspective views of one half of a lower section 30 of a two-stagegasification reactor, with FIG. 2 depicting a side view, FIG. 3depicting a top view, and FIG. 4 depicting an end view. Included inthese views are dashed lines for an x, y, z cartesian coordinate system(i.e., 206, 208, and 210 for the x,y,z axes, respectively) with itsorigin 212 centrally located within the lower section 30 of thetwo-stage gasification reactor, the x-axis 206 spanning the depth of thereactor lower section, the y-axis 208 spanning the length of the reactorlower section, and the z-axis 210 vertically oriented from the origin212 through the center of the reactor upper section 40. This coordinatesystem will be useful to help fully explain details of the two-stagegasification reactor design.

According to some embodiments of the present disclosure, a primary feednozzle 60 may be centrally located, substantially in line with y-axis208, on each of the terminal ends 202 of the horizontal lower section 30of the two-stage gasification reactor. The primary feed nozzle 60 mayintroduce the dry or slurried carbonaceous feedstock into the lowersection 30 of the reactor so that the feedstock may be reacted viacombustion processes described above. In addition to the primary feednozzle 60, in some embodiments, there may be at least two secondary feednozzles 200 a and 200 b with at least one secondary feed nozzle locatedon each of the terminal ends 202 of the horizontal lower section 30 ofthe two-stage gasification reactor.

In one or more embodiments, there may be at least two secondary feednozzles, such as one located on each of the terminal ends 202 of thehorizontal lower section 30 of the two-stage gasification reactor. Insome embodiments, there may be two secondary feed nozzles at each of theterminal ends 202 for a total of four secondary feed nozzles. Thesecondary feed nozzles 200 a (and 200 b if present) may introduce asecondary liquid hydrocarbon feedstock into the lower section 30 of thereactor so that it may be reacted by combustion processes as describedabove. In some embodiments, the secondary liquid hydrocarbon feedstockand the primary dry or slurried carbonaceous feedstock may be introducedinto the lower section 30 of the reactor substantially simultaneously.In other embodiments, the introduction of the secondary liquidhydrocarbon feedstock into the lower section 30 of the reactor may occurintermittently, while the introduction of the primary dry or slurriedcarbonaceous feedstock may be continuous while the gasification reactoris in operation. In one or more embodiments, there may be substantiallyno introduction of primary dry or slurried carbonaceous feedstock intothe lower section 30 via primary feed nozzles 60 and 60 a. In theseembodiments, a dry or slurried carbonaceous feedstock may be provided toupper section 40 by nozzle 80 and the lower section 30 may be fed therecycled dry char and ash produced by the upper section 40 by feednozzles 90 and 90 a along with secondary liquid hydrocarbon feedstockprovided by secondary feed nozzles 200 a and 200 b.

Further, and as illustrated in FIGS. 2-4, the secondary feed nozzles 200a and 200 b are designed to introduce the liquid hydrocarbon feedstockvia secondary feed vectors 204 a and 204 b into the lower section 30 ofthe reactor so that the liquid hydrocarbon feeds maintain a verticalsymmetry within the lower section 30 of the reactor with the primaryfeed vector, approximated by the y-axis marker 208, of the primary feednozzle 60. The design of the secondary feed nozzles 200 a and 200 b,including their respective placement on the terminal ends 202 of thehorizontal lower section 30 of the two-stage gasification reactor andtheir feed vector 204 a and 204 b orientation, is an importantengineering consideration in order to create optimal flow andtemperature profiles within the gasification reactor by minimizingdisturbance to the feedstock flow along the primary feed vector (i.e.,the y-axis marker 208) of the primary feed nozzle 60, while avoidingplugging or other damage that may be caused by accumulated ash material.For example, in some embodiments a design of the primary feed nozzle 60and secondary feed nozzles 200 a and 200 b will allow for the primaryfeed vector (i.e., the y-axis marker 208) from the primary feed nozzle60 and the secondary feed vectors 204 a and 204 b, from secondary feednozzles 200 a and 200 b, to intersect at a feed intersection point,approximated by the origin 212 of the coordinate system. In one or moreembodiments, the feed intersection point (i.e., origin 212) may becentrally located within the lower section 30 of the reactor at thepoint where the primary feed vector (i.e., the y-axis marker 208), thex-axis marker 206, and the z-axis marker 210 meet.

However, in one or more embodiments, the secondary feed vectors of thesecondary feed nozzles may be oriented towards a point that is lower onthe z-axis marker 210 than the location of the origin 212 (i.e. closerto the bottom of the reactor lower section 30). In these embodiments,the primary feed vector of the primary feed nozzle 60 may still beoriented towards the origin 212 (i.e. along the y-axis marker 208) or itmay be oriented to a point that is lower on the z-axis marker 210 thanthe location of the origin 212 (i.e. it may form a vector lower on thez-axis 210 but parallel to the y-axis marker 208). The generalorientations described in this paragraph may allow for an increase inthe temperature around the area leading to the quench chamber 32,thereby facilitating smooth slag flow to the quench chamber 32.

In general, the placement of secondary feed nozzles are independent ofeach other and may be anywhere on the terminal ends 202 of thehorizontal lower section 30 of the two-stage gasification reactor aslong as the feed vectors of the feeds being introduced into the lowersection 30 of the reactor meet at the feed intersection point (i.e., theorigin 212). In some embodiments, a secondary feed vector 204 a or 204 bmay form an angle with respect to the primary feed vector (i.e. y-axismarker 208) of about +/−1-45 degrees, or in some embodiments of about+/−5-30 degrees, and in yet further embodiments of about +/−10-20degrees. Independent of the above consideration, a secondary feed vector204 a or 204 b may form an angle with respect to the x-axis marker 206of about +/−1-45 degrees, or in some embodiments of about +/−5-30degrees, and in yet further embodiments of about +/−10-20 degrees. Also,a secondary feed vector 204 a or 204 b may form an angle with respect tothe z-axis marker 210 of about +/−145 degrees, or in some embodiments ofabout +/−5-30 degrees, and in yet further embodiments of about +/−10-20degrees. Further, the alignment of each particular feed vector may besubstantially unrelated to the alignment of another secondary feedvector. However, in order to maintain the proper symmetry of thesecondary feed vectors to obtain optimal flow conditions within thereactor, it may be necessary to align each secondary feed vector so thatthere is a complementary secondary feed vector that forms the oppositeangle with respect to the coordinate system. For example, if there isone secondary feed nozzle that has a secondary feed vector that foams a45 degree angle with respect to the primary feed vector (i.e. y-axismarker 208) then it may be beneficial for there to be another secondaryfeed nozzle that forms a −45 degree angle with respect to the primaryfeed vector (i.e. y-axis marker 208).

In one or more embodiments, it may be beneficial for attaining optimalfeedstock flow conditions within the reactor if the flow of feedstockfrom one secondary feed nozzle 200 a or 200 b on one terminal end 202 isdirectly opposed by the flow of feedstock from another secondary feednozzle (not shown) located on the opposite terminal end (not shown) ofthe lower section 30 of the gasification reactor (i.e., the twofeedstock vectors form a straight line through the feed intersectionpoint from one terminal end to the other). In one or more embodiments,each terminal end 202 of the lower section 30 of the gasificationreactor may have the same number of secondary feed nozzles attachedthereto, with each secondary feed nozzle having a feed vector that isdirectly opposed by another secondary feed nozzle's feed vector on theopposite terminal end of the lower section 30 of the gasificationreactor. The above considerations regarding the feed vectors of thesecondary feed nozzles may serve to provide optimal operating conditionsfor the gasification reactor by reducing the possibility for secondaryliquid hydrocarbon feedstock spray contact or impingement upon theinterior reactor wall surfaces, reducing any material disruption of theprimary dried or slurried carbonaceous feedstock from the primary feednozzles, and ensuring adequate temperature (e.g., above the ash fusiontemperature of the feedstock ash) in the area around the reactor-lowersection 30 leading to the quench chamber 32.

The dry or slurried carbonaceous feedstocks introduced into the lowerreactor section by the primary feed nozzle may include lignite,sub-bituminous coal, bituminous coal, petroleum coke, char separatedfrom the products of the upper section of the gasification reactor, andmixtures thereof. If the feedstock is a slurried carbonaceous feedstock,the carrier liquid for the carbonaceous materials therein may includewater, liquid CO₂, petroleum liquid, or any mixture thereof. The liquidhydrocarbon feedstock introduced into the lower reactor section by thesecondary feed nozzles may include pyrolysis oil, vacuum resid, pitch(including solvent deasphalted pitch), coal tar, phenolic materials Fromlow-temperature gasification processes, solvent blowdown from acid gasremoval units (AGRs), or mixtures thereof. The liquid hydrocarbonfeedstocks may be described more specifically as follows: vacuum residis high molecular weight/boiling point fraction of a refinery crudeslate, pitch is high molecular weight/boiling point by-product ofhydrocracking, phenolic materials are byproducts created when coolingsyngas from low-temperature gasification processes, and solvent blowdownstreams from AGRs contain solvents (e.g., amines, glycols, methanol,etc.) and contaminants (e.g., BTX, tars, hydrocarbons, etc.) thatrequire purging from the AGRs.

In some embodiments, the liquid hydrocarbon feedstock may be at most 10percent, at most 20 percent, at most 40 percent, at most 60 percent, orat most 80 percent by weight of the total feedstock blend (i.e., dry orslurried feedstock and/or recycled dry char plus the liquid hydrocarbonfeedstock) introduced into the lower section of the gasificationreactor. In one or more embodiments, the secondary feed nozzles of thelower section of the gasification reactor may atomize the liquidhydrocarbon feedstock with nitrogen, recycled synthesis gas, air, oxygenenriched air, oxygen, steam, or mixtures thereof. Atomizing the liquidhydrocarbon feedstock being introduced into the lower section of thegasification reactor may be important to ensure optimal combustion ofthe total feedstock blend.

Embodiments of the present disclosure may provide at least one of thefollowing advantages. Increasing the feedstock flexibility within agasification process thereby increasing the capital efficiency andutility of a gasification reactor having the secondary feed nozzlesdescribed herein. Additionally, some of the liquid hydrocarbonfeedstocks mentioned above may be generated by a facility that is unableto use those feedstocks. In these instances, the particular liquidhydrocarbon feedstocks may be collected and transported to anotherlocation for sale, use, or destruction. Embodiments, of the presentdisclosure may avoid the potentially risky and costly transportation ofthe liquid hydrocarbons and uncertain market conditions (if they aresold) by facilitating the internal use of these feedstocks in agasification process/reactor disclosed herein. Further, in someembodiments, it may be possible to vary the amount of liquid hydrocarbonfeedstock introduced into the lower section of a gasification reactorwithout requiring a reactor shutdown, thereby facilitating continuousoperation of the gasification reactor if a reduction or increase in theliquid hydrocarbon feed is desired or if the liquid hydrocarbon streambecomes unavailable. Additionally, it is envisioned that the performanceof existing gasification reactors may be able to be improved in the waysmentioned above by simply installing at least two secondary feed nozzleson the lower reactor body of the gasification reactor so that liquidhydrocarbon feedstocks may be introduced into the lower reactor bodyduring the gasification process to supplement the feedstock provided bythe primary feed nozzle,

Therefore, the present disclosure advantageously provides for theproduction by gasification of a high value product (H₂) by usinglow-value by-products (e.g. the liquid hydrocarbon feedstocks). Hydrogenis a high value product in a refinery setting because it is needed forvarious crude oil hydroprocessing operations, such as sulfur removal andhydrocracking. In contrast to the present disclosure, often hydrogen isgenerated in a refinery setting by reforming (consuming) a high valueliquid or gas. The gasification processes disclosed herein can use lowervalue feedstock to produce hydrogen with the added flexibility tooperate with a wider feedstock variety. In addition, the liquidhydrocarbon feedstock consumes comparatively less oxygen for a givenamount of produced syngas than the solid dried or slurried carbonaceousfeedstock, so complimenting the primary feedstock with the liquidhydrocarbon feedstock will serve to reduce overall oxygen consumptionwithin the gasification reactor.

Although only a few example embodiments have been described in detailabove, those skilled in the art will readily appreciate that manymodifications are possible in the example embodiments without materiallydeparting from this invention. Accordingly, all such modifications areintended to be included within the scope of this disclosure as definedin the following claims. It is the express intention of the applicantnot to invoke 35 U.S.C. §112(f) for any limitations of any of the claimsherein, except for those in which the claim expressly uses the words‘means for’ together with an associated function.

What is claimed:
 1. A gasification process, comprising: (a) introducinga liquid hydrocarbon feedstock and at least one of a dry feedstock or afirst slurried feedstock into a reactor lower section, wherein the atleast one dry feedstock or first slurried feedstock is introducedthrough two primary feed nozzles while the liquid hydrocarbon feedstockis introduced through at least two secondary feed nozzles; (b) partiallycombusting the feedstocks in the reactor lower section with a gas streamcomprising an oxygen-containing gas or steam to evolve heat and formproducts comprising hot synthesis gas; (c) passing said hot synthesisgas from step (b) upward into a reactor upper section; and (d)introducing a second slurried feedstock into said reactor upper section,whereby heat from said hot synthesis gas supports reaction of the secondslurried feedstock by pyrolysis and gasification reactions.
 2. Thegasification process of claim 1, wherein introducing the liquidhydrocarbon feedstock and at least one of a dry feedstock or a firstslurried feedstock into the reactor lower section occur simultaneously.3. The gasification process of claim 1, wherein introducing the liquidhydrocarbon feedstock into the reactor lower section occursintermittently, while introducing the at least one dry feedstock orfirst slurried feedstock is continuous.
 4. The gasification process ofclaim 1, wherein liquid hydrocarbon secondary feed vectors of the atleast two secondary feed nozzles are oriented so they maintain avertical symmetry within the reactor lower section with a primary feedvector of the primary feed nozzle.
 5. The gasification process of claim1, wherein a secondary feed vector of the liquid hydrocarbon feeds fromthe at least two secondary feed nozzles and a primary feed vector of theprimary feed from the primary feed nozzles intersect at a feedintersection point that is substantially in the center of the lowerreactor body.
 6. The gasification process of claim 5, wherein secondaryfeed vectors of the liquid hydrocarbon feeds from the at least twosecondary feed nozzles intersect in the center of the lower reactor bodyand form a straight line through the center of the lower reactor bodyfrom one terminal end of the reactor lower section to the other terminalend.
 7. The gasification process of claim 1, wherein at least onesecondary feed vector of the at least two secondary feed nozzles formsan angle from about +/−1-45 degrees with respect to a primary feedvector of the two primary feed nozzles.
 8. The gasification process ofclaim 1, wherein at least one secondary feed vector of the at least twosecondary feed nozzles forms an angle from about +/−1-45 degrees withrespect to an axis spanning the depth of the center of the reactor lowersection.
 9. The gasification process of claim 1, wherein the at leasttwo secondary feed nozzles atomize the liquid hydrocarbon feedstock withair, oxygen-enriched air, oxygen, steam, or mixtures thereof.
 10. Thegasification process of claim 1, wherein an amount of total feedstockintroduced into the reactor lower section is at most 60 weight percentliquid hydrocarbon.
 11. The gasification process of claim 1, wherein theliquid hydrocarbon feedstock comprises pyrolysis oil, vacuum resid,pitch, coal tar, phenolic materials from low-temperature gasificationprocesses, solvent blowdown from acid gas removal units (AGRs), ormixtures thereof.
 12. The gasification process of claim 1, wherein thedry feedstock and first slurried feedstock comprises at least one oflignite, sub-bituminous coal, bituminous coal, petroleum coke, char, andmixtures thereof.
 13. A two-stage gasification reactor, comprising: areactor lower section comprising: (a) a lower reactor body; (b) twoprimary feed nozzles, configured to introduce at least one of a dryfeedstock or a first slurried feedstock, located on opposing terminalends of the lower reactor body; and (c) at least two secondary feednozzles, configured to introduce a liquid hydrocarbon feedstock, locatedon the lower reactor body; a reactor upper section comprising: (a) anupper reactor body; (b) at least one upper feed nozzle, configured tointroduce at least one of a dry feedstock or a first slurried feedstock,located on the upper reactor body; and (c) an outlet.
 14. The two-stagegasification reactor of claim 13, wherein the at least two secondaryfeed nozzles are oriented so they provide feeds along secondary feedvectors that maintain a vertical symmetry within the reactor lowersection with feeds along primary feed vectors from the primary feednozzles.
 15. The two-stage gasification reactor of claim 13, wherein theat least two secondary feed nozzles and the primary feed nozzle areoriented so they provide feeds along feed vectors that intersect at afeed intersection point that is substantially in the center of the lowerreactor body.
 16. The two-stage gasification reactor of claim 13,wherein the at least two secondary feed nozzles are located on opposingterminal ends of the lower reactor body so that each terminal endpossesses the same amount of secondary feed nozzles.
 17. The two-stagegasification reactor of claim 16, wherein each secondary feed vector ofeach secondary feed nozzle on one terminal end is oriented to form astraight line with a secondary feed vector from a secondary feed nozzleon the opposing terminal end.
 18. The two-stage gasification reactor ofclaim 13, wherein at least one secondary feed vector from the at leasttwo secondary feed nozzles forms an angle from about +/−1-45 degreeswith respect to a primary feed vector from the two primary feed nozzles.19. The two-stage gasification reactor of claim 13, wherein at least onesecondary feed vector from the at least two secondary feed nozzles formsan angle from about +/−1-45 degrees with respect to an axis spanning thedepth of the center of the reactor Lower section.
 20. A method forimproving a two-stage gasification reactor, comprising: installing atleast two secondary feed nozzles on a lower reactor body for introducinga liquid hydrocarbon feedstock into the lower reactor body to supplementa primary feedstock comprised of a dry feedstock or a slurried feedstockthat is introduced through a primary feed nozzle.